Rotor Blade Core Panel Balancing Without Adhesive Adjustment
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Solution Overview
Problem
Conventional methods for balancing rotor blades in rotary wing aircraft are time-consuming due to variations in weight distribution and moments, requiring individual checking and adhesive application to achieve target criteria.
Innovation Solution
A method involving additive manufacturing to create a core panel with varying properties across the span, chord, and thickness, which is designed using an algorithm to achieve target weight distribution and moment without the need for adhesive, by measuring sub-components' weights and determining the core's configuration to form a balanced rotor blade sub-assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional procedures are used to balance rotor blades by individually checking and applying adhesive, then the target weight distribution and moment criteria can be achieved, but the process is time-consuming
Solution Approach 1:
The core is designed and manufactured with predetermined weight distribution properties before assembly. The algorithm calculates the exact core configuration needed to achieve target balance criteria, eliminating the need for post-assembly adhesive application and individual blade checking.
Solution Approach 2:
The invention changes the physical parameters of the core (density, shape, volume distribution) to directly achieve the desired weight distribution. By varying core density across different blade sections and adjusting core geometry, the target moment and weight distribution are achieved inherently without adhesive modification.
2Manufacturing precision
If adhesive is applied to achieve target weight distribution, then balancing criteria can be met, but the process complexity and time increase
Solution Approach 1:
The invention extracts the balancing function from the adhesive application process and transfers it to the core design and manufacturing process. The core itself carries the balancing function through its predetermined weight distribution, eliminating the need for adhesive as a balancing tool.
Solution Approach 2:
The core is designed to self-balance the rotor blade through its inherent weight distribution properties. The algorithm-determined core configuration automatically provides the necessary balance correction without requiring external adhesive application or manual adjustment during assembly.
3Ease of manufacture
If rotor blades are manufactured using multiple components, then assembly flexibility is achieved, but weight variation between blades increases
Solution Approach 1:
The core is designed with locally varied density and geometric properties to achieve precise weight distribution. Different sections of the core have different densities and volumes, allowing the single core component to provide both structural function and precise balancing function, compensating for variations in other blade components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time required for balancing rotor blades and eliminates the need for adhesive, resulting in a more efficient and precise weight distribution and moment, enhancing the dynamic balancing of rotor blades.
Implementation Method 1
the core is fabricated via an additive manufacturing process
Data Source
AI summary
A method of forming a balanced rotor blade assembly includes measuring a weight of a plurality of sub-components of the rotor blade assembly excluding a core. A configuration of a core of the rotor blade assembly is determined. In combination, the core and the plurality of sub-components achieve a target weight distribution and moment. The core is then fabricated and assembled with the plurality of sub-components to form a rotor blade sub-assembly.